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Alternator Brush Replacement
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Posted by Derek (more from Derek) on Wed, 8 Jan 2003 17:59:25 Share Post by Email
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Hi there,

I know there have been some posts on this B.B. about brush replacement but I thought I would share my own experience (just finished a half hour ago). My 94 cs has about 220 kms and I had noticed the car was getting hard to start on our cold winter mornings. Battery was 4 yrs. old so I thought a replacement was due. Sure enough on the way to buy the battery my battery light flickered on and off on the dash and the voltage was fluctuating up and down from 10 volts to 14 volts. I had replaced the voltage regulator assembly on my 86 a few years ago but thought I'd just try the brushes on this car. I got both brushes, the correct bosch part no., from a local alt. rebuilding place.

Anyway, it was very, very easy and the alternator stays on the car. I didn't have to unbolt the dipstick tube and on my 94 there is more than enough room to reach down and unscrew the voltage regulator from behind the alternator. Both screws came out quite easily. Before this unbolt both alternator connections and be sure to disconnect the negative battery terminal. Once the voltage regulator is out snip off the pigtails at the back of the brush holders (my brushes were both right down past the 5 mm min.) Take a drill and a very small drill bit and drill out the brush pigtails from behind. The brushes come out quite easily this way and the springs did not go flying. I tinned the new brush pigtails with some solder and inserted them through the springs and into the holders, the pigtails come out the back, then it is simply a matter of pulling them through so that about 10 mm of brush is showing and then soldering them in place from behind.

Snip off the remaining pigtails, compress the brushes and put an elastic band around them to hold them in place. Lying on the engine and with a good worklight you can see how the reulator goes back into the alt. Start both screws (this took a bit of time) once they have bit cut the elastic holding the brushes in place and pull it out. Tighten the screws, check for any hoses you may have knocked off, reconnect both alt. connections and the battery and you're done. 14.4 volts right away and holding. Total cost 4.00 cdn and 1 hr and 15 min of my time. Cheaper than buying the whole bosch voltage regulator as well.

Anyway, sorry it is so long but I hope this helps anyone with this kind of problem. I'm familiar with 9000's but no more or less adept mechanically than anyone else, if I can do it you can.

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